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Unread 07-16-2014, 08:45 AM   #1
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Default Potentiometer to MCOR4 conversion tips?

I recently acquired a 96 48v two seater, cart has been sitting for about 1 1/2 years. After replacing the batteries and battery cables, it appears the potentiometer has gone bad. 1/2 pedal or less acceleration works and anything beyond has no power to accelerate.

After being quoted a healthy amount for the repair to convert to MCOR, I've picked up the conversion kit at the local dealer with MCOR4. It has instructions, but I am hoping some of the experienced members here could share any tips, tools that might be especially helpful or other advice before I tackle this project.

I will likely be doing it outside on a concrete slab with jack / stands instead of hauling the cart 1 hour each way (and having to rent/borrow a trailer). I'm fairly mechanically and electrically savvy with a garage full of tools, but access will be limited once I head to the beach!

Ultimately I plan to bring it home this winter, but was hoping to get some use of it this summer before anything more major is completed. Thanks in advance.
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Unread 07-16-2014, 08:58 AM   #2
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Default Re: Potentiometer to MCOR4 conversion tips?

Curious why you didn't just get a new potentiometer and make a straight swap. The original lasted nearly 20 years.
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Unread 07-17-2014, 10:36 PM   #3
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Default Re: Potentiometer to MCOR4 conversion tips?

I originally had the same thought. As being the quickest and easiest option.

The only source to locate a replacement appeared to be ebay and not available from the dealer, although I didn't specially ask I they could get one.

After explaining the issue multiple dealers, the second being my local club car both seemed to push this as the recommended fix.

I bought the parts kit with MCOR4 for less than I could locate the potentiometer - $250 out the door.
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Unread 07-28-2014, 09:04 PM   #4
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Default Re: Potentiometer to MCOR4 conversion tips?

UPDATE - I completed the conversion this weekend, pretty painless overall if mechanically and electrically inclined. Instructions were pretty good - step by step, just had to go slow and think thru it.

All in all cart is up and running again, and I saved a bundle doing it myself. Probably a 3 hour job if you've done it before. It took me 5-7 total since I had to span over two days and put away in between sessions.

Save your bolts, you need to reuse all but one! A nice kit to be able to convert from 1996 to 201X.
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Unread 07-28-2014, 09:38 PM   #5
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Default Re: Potentiometer to MCOR4 conversion tips?

Hey, thanks for the info. My '96 Regen 1 is still running fine on the old potentiometer, but I've been wondering what I would do it if craters (they must have been a headache because CC went back to using V-Glides within a year or so of use).

I didn't realize there was a kit available - so I will lock that in my memory banks. Do you have a part#?
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Unread 07-30-2014, 08:09 PM   #6
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Default Re: Potentiometer to MCOR4 conversion tips?

Quote:
Originally Posted by joesam View Post
Hey, thanks for the info. My '96 Regen 1 is still running fine on the old potentiometer, but I've been wondering what I would do it if craters (they must have been a headache because CC went back to using V-Glides within a year or so of use).

I didn't realize there was a kit available - so I will lock that in my memory banks. Do you have a part#?
Club Car Part #103951901

By Default it will come with an MCOR3 - the dealer was willing to swap the MCOR3 from the kit with an in-stock MCOR4.
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Unread 07-31-2014, 05:40 PM   #7
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Default Re: Potentiometer to MCOR4 conversion tips?

Thanks - I've noted that part# on the inside cover of my maintenance manual - there if I need it!
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Unread 07-31-2014, 06:16 PM   #8
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Default Re: Potentiometer to MCOR4 conversion tips?

Quote:
Originally Posted by jroeiii View Post
Club Car Part #103951901

By Default it will come with an MCOR3 - the dealer was willing to swap the MCOR3 from the kit with an in-stock MCOR4.
MCOR3 is no longer available. New number is...

AM293201 - KIT, PRE-MCOR TO MCOR4 CONV
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Unread 07-31-2014, 07:11 PM   #9
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Default Re: Potentiometer to MCOR4 conversion tips?

Thx Tahoe!
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